I. Safety Precautions

Attention

The equipment manufactured by our company, if used without due attention to safety, could pose significant risks of injury to individuals. Therefore, under all circumstances and operating conditions, users must strictly adhere to the operating guidelines and prioritize personal safety at all times. Please read this manual carefully!

The copyright of this manual, as well as all illustrations and images used herein, is owned by our company. No individual or organization may reproduce, modify, cite, or redistribute any part of it without our company’s prior written authorization; otherwise, our company will pursue legal action against the offender.

This manual may not describe certain device features; however, the company assumes no responsibility for these features during actual use, as they are provided solely for informational purposes.

During the review and editing process of this manual, we conducted a thorough audit; however, inconsistencies and inaccuracies may still exist. We will periodically check the content within the manual and reserve the right to make revisions without prior notice.

This manual explains the latest technology of our company's product series and summarizes the key technical features of each device. The product line features a variety of designs, including different sizes, distinct functional roles, diverse installation methods, and varying component configurations. If you need to determine the appropriate model for your equipment, please contact our company.

As an equipment manager, the following situations will result in the equipment being taken out of use:

-- The equipment is not properly installed and secured;

-- The device is not properly connected to the power source;

-- The air unit failed to obtain a stable, clean air supply;

-- Safety devices of the equipment are not properly installed;

--The equipment is in the installation and construction phase;

-- After installation, the integrity of the equipment was not checked;

--The equipment includes various installation tools and lifting devices stored within the device itself;

-- Equipment status regarding inspection and maintenance;

-- The electrical components of the equipment were wetted by cleaning water;

Attention

Under normal usage, our company will fulfill the warranty obligations stipulated in the contract. However, if the user makes unauthorized modifications to the equipment, fails to follow the instructions outlined in this manual, or in any of the following circumstances, our company will suspend the warranty obligations.

-- Equipment installed incorrectly, either not according to the manual or without receiving technical support from our company;

-- Removing safety devices preset on the equipment or disabling equipment that shields safe operation features;

-- Equipment used in serious violation of operational guidelines, failing to follow the manual's requirements;

– Beyond the agreed warranty period;

-- Equipment whose components have been privately modified, with or without the company's approval, or where parts have been added or removed;

-- Unauthorized replacement of non-genuine parts without the company's permission or approval resulted in equipment malfunction;

– During warranty service, it is impossible to provide repair conditions that ensure personal safety;

-- Do not use the equipment in high-risk, hazardous, or outdoor environments without our company's approval;

If the device is transferred for sale, please pass this manual on to the new user. If this manual is lost, you may request a replacement directly from our company.

Attention

This manual outlines the product's various performance features and highlights essential safety guidelines and precautions for proper usage, ensuring both the operator's safety and the reliable operation of the equipment.

To better illustrate the device's structure, this manual includes several detailed illustrations of local components, as well as equipment diagrams that conceal certain parts. When using the device, be sure to inspect—especially the safety components and the integrity of other key parts.

This manual uses text and images to inform users about the product's performance, installation, operation, maintenance, and troubleshooting.

This manual outlines the various configurations available for the current model of product. Please note that the equipment you’ve purchased may not include all of these features, as your device was customized according to your specific requirements. Therefore, the information provided in this manual might differ slightly from the actual equipment you received.

This manual reflects the latest technical standards at the time the product is sold. Although the company may subsequently introduce technical updates to the product, this manual will remain valid. Additionally, the company reserves the right to revise the manual as needed to align with new standards—without providing prior notice or replacing previous versions of the manual.

Our company will continuously optimize our products, and we would appreciate any feedback or suggestions aimed at improving either the product or this manual.

1. Sources of harm to avoid: The equipment primarily poses risks from two major sources:

1.1、Mechanical Injury

1. Mechanical hazards from the equipment originate from its various moving parts; we will specifically mark these areas in the manual.

2. Electric Motor Impeller Guard

From equipment installation through to the start of production, there is no need to remove the motor impeller guard. It may only be taken off temporarily during maintenance for calibration purposes. Therefore, unauthorized or non-professional maintenance personnel must not dismantle this guard. After maintenance is completed, the guard should be promptly reinstalled and reset—never operate the equipment with the guard removed.

3. Fan Inlet Port

The fan inlet is equipped with a filter screen, which does not need to be removed during the process from equipment installation to production launch. The filter screen may only be taken out during maintenance and cleaning operations—and after such work, it should be promptly reinstalled and reset. Under no circumstances should the equipment be used while the filter screen remains detached.

1.2、Electrical Shock Injury

1. Electrical shock hazards from the equipment originate from the motor, control cabinet, cables, and cable connections.

2. A complete grounding system must be installed to prevent accidental leakage currents, short circuits, and potential electrostatic hazards that could harm individuals.

2. Basic Principles for Safe Operation

2.1. Absolutely no touching of rotating parts that are in operation, and be cautious of potential hazards such as accidental falls or collisions.

2.2 When performing maintenance or cleaning operations on the equipment, ensure that the main power supply is switched off and take precautions to prevent anyone else from turning the main power back on.

2.3、Electrical connection, wiring inspection, and maintenance of the control section must be performed by qualified electricians; unauthorized personnel are strictly prohibited from operating.

2.4. Do not remove the safety protection devices that come with the equipment itself, and perform safety checks according to the notes in this manual.

2.5. Avoid all heat source areas and strictly prohibit direct physical contact. Also, ensure that no person stands in the potential splash trajectories of any components.

2.6. For all moving parts, ensure that no pinching injuries occur during rotation.

2.7. Users should establish a post responsibility system and strengthen their awareness of safe production.

II. Basic Information on the Equipment

1. Scope of Application

The centralized material suction system is widely used for pneumatic conveying and pneumatic blending of modified plastics.

Features:

1. The centralized material-suction system can effectively reduce energy consumption in modified plastic material transportation, minimize workshop noise, and decrease the need for feeding equipment.

2. The centralized material suction system enables intelligent control of the material conveying fan.

3. Simple structure and easy to clean.

2. Working Principle

System Control: The fan uses a multi-unit, one-backup configuration; the filter tank features backflushing for self-cleaning.

Use one as a backup; initiating the reverse-blow cleaning process does not disrupt production across the entire line. There is one master control box, with each workstation equipped with a separate touchscreen for controlling its specific production line. The fan features intelligent variable-frequency control, and both inlet and outlet pipes of the self-cleaning filter tank are fitted with pressure transmitters to continuously monitor changes in main negative-pressure line pressure and detect any potential blockages in the filter tank—enabling timely adjustments to fan power and automatic tank-cleaning cycles. This ensures consistent pipeline pressure while also helping to conserve energy.

3. Equipment Configuration

The centralized material-suction system is custom-designed according to the air volume required for pneumatic conveying on the production line. Different system configurations are available, and specific parameters will be set based on contract requirements.

4. Special Notes

4.1、The specific model of equipment configuration may vary.

During the equipment configuration process, the following situations either exist or need to be configured. The equipment being configured will differ from standard centralized material-suction systems and must be explicitly noted:

1) That needs to be integrated with other devices;

2) Where the ambient minimum temperature exceeds -35°C;

3) Used at temperatures exceeding 100°C;

4) The materials possess special properties such as exothermic reactions, steam generation, flammability, explosiveness, and tendency to stick or adhere.

4.2、The following factors highlight the differences in equipment:

Pipe material, pipe length, branch pipe quantity, installation method, motor power, power supply characteristics, protective measures, and more

III. Equipment Installation

1. Equipment Loading and Unloading

1) The centralized material suction system typically uses component-handling forklifts for loading and unloading, both of which must follow specific operational guidelines. These tasks should be carried out exclusively by professionally trained personnel qualified to operate specialized equipment.

2) The forklift's attachment equipment should have its movable components removed to prevent them from falling off during lifting operations.

3) During loading and unloading operations, use forklifts equipped with appropriate capacity and compliant with safety regulations. As shown in the diagram, carry out the loading and unloading process carefully, ensuring proper control of the center of gravity. After lifting, operate at a slow speed to maintain stable movement and balance.

4) Personnel should work from a safe location and are prohibited from standing directly beneath the equipment.

2. Equipment Installation Foundation

1) The centralized material-suction system equipment, as a shared system component, should have its communication mode agreed upon during the ordering process if it needs to be integrated and coordinated with other equipment, ensuring convenient debugging and operation in the future.

2) The filter tank and fan unit of the centralized material-suction system are installed using bolts or welding, and securely fixed horizontally to the mounting base.

3) The design load-bearing capacity of the foundation is typically 1.5 to 2 times that of the equipment.

3. Precautions During Installation

1) During the installation process, the various pieces of equipment within the process should be arranged in an appropriate sequence for installation.

2) When installing the equipment, pay attention to its orientation, ensuring that the installation adheres to safety principles while also optimizing production efficiency, facilitating maintenance and repairs, and enabling convenient cleaning.

3) The external installation components used during installation must be provided by the user or prepared by the installation company.

4) If the equipment is not installed or used for an extended period, it must be stored in a dry, well-ventilated, and cool environment, ensuring proper anti-slip measures, balanced weight distribution, and stable operation.

4. Equipment Power Supply Installation

1) All operations related to the electrical circuit must be carried out by qualified professionals. Ensure strict adherence to standards by selecting high-quality electrical components and cables of appropriate capacity for circuit installation.

2) When installing the equipment's power supply, thoroughly inspect the power lines to ensure no phase loss or voltage mismatches occur.

3) After installing the power supply, verify the functionality of all buttons and indicator lights on the electrical control box. If any component fails, address the issue promptly—do not proceed with direct equipment operation until it is fully functional.

4) The basic configuration of the electrical control box should include the following components: a three-phase power input indicator light, a start button, a start indicator light, a stop button, and a stop indicator light.

4. Equipment Debugging

1. Instructions Before Debugging

At the time of出厂, all equipment has undergone testing and met quality inspection standards. After reviewing the manufacturing requirements, the equipment is then released for shipment.

After users have completed installing the equipment, they must carefully clean out any remaining debris and dust inside the device. If the equipment has been left unused for an extended period, or if more than 3 months have passed between the time it was activated and its出厂 date, it should be thoroughly inspected and cleaned before being powered on and operated.

Attention

During all types of debugging, please use the raw materials required for production for testing; do not substitute them with other materials.

After the equipment installation and commissioning are completed, it is still necessary to clean the inside of the equipment.

During all types of commissioning, operators and on-site inspectors should not leave their posts until the commissioning is complete.

Various types of debugging cannot be performed out of sequence, nor can they span across time.

2. Prepare the assignment

Inspect the equipment interior for any potential debris or tools, and proceed to clean the inside of the device.

Check whether the equipment's power supply is functioning properly, including the main motor power supply, safety device power supply, and more.

Check whether the device accessories are functioning properly.

Check whether each connecting pipe is sealed.

3. Functional Component Testing

After the equipment is powered on, you should first check whether the functional accessories are operating properly.

After the attachment check is completed, start the equipment and verify whether the motor rotation matches the markings on the motor. If not, make adjustments promptly.

4. Run and Debug

After the equipment completes preparation and functional debugging, it enters the operational commissioning phase.

Proceed step by step according to the following method:

1) Start the equipment for 5 minutes, monitoring at all times for any unusual or disruptive noises during operation. If such noises are detected, immediately stop the equipment and investigate further. Also, check each connecting pipe for air leaks—if any are found, promptly halt the equipment and reconnect the seals securely. Finally, verify that the operating current remains within normal limits; if not, immediately use the stop button or emergency stop button to cut off the power supply.

2) During normal operation, after running continuously for 1 hour, check all parts of the equipment for air leaks, abnormal noises, or any other issues. If any problems are detected, take immediate action.

5. Post-Debugging Inspection

1) During debugging and after the debugging period concludes, the following components must be inspected:

2) The temperature of the vibration motor should all be below 60 degrees Celsius;

3) No air leakage at the pipe connections;

4) All connecting bolts and anchor bolts on the equipment show no signs of loosening.

V. Occupational Safety and Health

1. Safety Precautions in Production

1) When operating the equipment, pay attention to all the warning areas indicated on the device.

2) Equipment with removed safety devices must not be used.

3) When the equipment is running, do not use any tools to reach into the air inlet.

4) When cleaning or repairing equipment, be sure to disconnect the power supply and use warning signs or lockout/tagout procedures to prevent unauthorized personnel from turning the power back on.

2. Planning and Responsibility

1) Use equipment that has been properly debugged and qualified for production, and establish a series of pilot production plans to better coordinate and align the various stages of the manufacturing process.

2) Establish a job responsibility system and assign trained professionals to perform all equipment operations. Ensure rational division of tasks to guarantee the smooth completion of production activities.

3. Pre-production Preparation

1) Before powering on the electrical control system, check whether the equipment area is ready for production conditions, and clear away any obstructions or debris.

2) Turn on the electrical control box switch and check whether the supply voltage and phase count are normal.

3) Before connecting the compressed air supply, check whether the air source is clean and dry (if necessary).

4) Inspect the equipment interior for any potential debris or tools, and thoroughly clean the inside of the device.

5) Check whether the equipment's power supply is normal, including the main motor power supply, safety device power supply, and others.

6) Check whether the device accessories are functioning properly.

7) Check whether the fan's rotation direction is correct.

4. Production Operations

1: System Components

1. This project consists of a centralized negative pressure system and a homogenization tank, with the homogenization bin linked to control the start and stop of the centralized negative pressure system.

2. Establish a connection via Ethernet; the network layout is shown in the diagram below:

3. To ensure the network establishes a normal connection, the electrical cabinet in each equalization bin must remain powered on.

Control panel touchscreen display for the crew:

Device control logic:

(1) The mode-switch button allows users to toggle the start/stop operation of the unit. When the button is set to “Unit Auto,” the start and stop of the centralized negative-pressure system will be controlled by the operation status of the homogenization bins—whenever any one of the homogenization bins is put into use, the centralized negative pressure system will begin running; conversely, once all homogenization bins are shut down, the centralized negative-pressure system will also turn off.

(2) When the button is set to "Unit Manual," the start and stop of the centralized negative-pressure system are controlled by the "Unit Start/Stop" button. Clicking the system's start/stop button will activate the negative-pressure system independently of the equalization bin's control. A green indicator on the button signifies that the unit is running.

3. Constant Voltage Control:

(1) The current system pressure value is displayed in real time at the top left corner. The pressure setting is indicated by a blue numerical value, which can be adjusted to define the desired system pressure. Once the unit starts running, the system compares the set pressure value with the real-time pressure reading. Using fuzzy PID control logic, it calculates the optimal output to regulate the operating frequency of the variable-frequency motor, thereby maintaining constant pressure effectively. The pressure setting is

The recommended range should be set between -20 kPa and -23 kPa.

4. Fault Reset:

If an abnormality occurs during operation, it can be reset using the fault reset button.

5. Other buttons:

“The Trend Screen” allows you to view the constant-pressure trend chart and the frequency-inverter motor frequency input trend by clicking the corresponding button; meanwhile, the “Alarm Screen” lets you check the current alarm messages.

“Manual control” and “system parameters” are used only during debugging and will not be discussed here.

6. Communication Status:

On the right side of the screen, you can now see the communication status and input status for each homogenization bin from C1 to C16. Communication abnormalities are indicated by a red "Offline" text, while normal communication connections are displayed accordingly.

“Online” in green font—small rectangles display gray to indicate that the warehouse is not yet operational, while green signifies it’s running.

6. Maintenance and Care

1. The Basic Principles of Maintenance

1) Implementing a regular maintenance plan can effectively extend the equipment's lifespan and better ensure safe production.

2) When repairing or maintaining the equipment, use components that are consistent with the equipment itself. Each maintenance and upkeep plan should be assigned to a dedicated person in charge and carried out by trained personnel.

3) During normal operation of the equipment, necessary maintenance measures should be taken for items such as keeping the exterior clean and checking the tightness of all fastening bolts, with a scheduled plan established accordingly.

4) When performing equipment maintenance and inspections, follow the safety operating procedures.

2. Equipment Cleaning

After continuous operation of the equipment, dust will accumulate inside the filter tanks, filter elements, or filter bags during the production process, requiring equipment cleaning when the maintenance cycle arrives.

When cleaning, please note the following points:

1) Please do not leave any of the cleaning tools used inside the equipment—after cleaning, they should be collected and stored together.

2) Use clean compressed air for cleaning and take appropriate protective measures to prevent eye injuries from particles blown up by the compressed air.

3) During machine clearing operations, the power should be physically disconnected.

4) When cleaning the equipment with water, pay attention to electrical safety and take appropriate isolation measures for the motor, electrical control box, and solenoid valves.

5) When cleaning, ensure that the equipment is not turned on and the electrical control box is de-energized to prevent others from accidentally switching on the power. Appropriate warning measures should also be implemented.

6) Do not use cleaning agents that are corrosive to the material of the device itself.

7) Equipment requiring hygiene standards should be cleaned using appropriate cleaning methods that meet the necessary requirements.

8) Do not use blunt or sharp tools for cleaning operations, as this may easily damage the inner surface of the equipment.

9) After cleaning the equipment, the safety devices should be reset.

3. Equipment Maintenance Plan

4. Possible Equipment Failures and Troubleshooting